ESL-HH-86-11-06

THERMAL STORAGE WITH ICE HARVESTING SYSTEMS DAVID E. KNEBEL, P.E. Vice-President Turbo Refrigerating Company Denton, Texas ABSTRACT Application of Harvesting Ice Storage Syst ems. Thermal storage systems are becoming widely accepted techniques for utility load management. This paper discusses the principles of ice harvesting equipment and their application to the multi-use environments. T h e potential for application of low dew point environments in terms of comfort and system energy consumption will also be discussed. Several case studies will be the installations of harvesting thermal storage systems. INTRODUCTION Load management is resource management for the electric utility company. The power plant and distribution network are significant investments, which yield the maximum return on investment when continuously used at or near full capacity. Diverse loads violate sound economic practice for the utility. One way of addressing load management for the air conditioning load is through thermal storage. This paper will discuss the application of ice harvesting equipment as a load management device for the electrical utility. By reducing the size of the installed chiller or by preventing chiller operation during peak periods, demand may be conserved. EQUIPMENT DESCRIPTION The Turbo Icemaking Heat Pump and Ice Generator is basically a simplified version of the Turbo Industrial Plate Ice Maker. The machine is a simple direct expansion refrigeration system whose evaporator consists of multiple vertical plates. The evaporator section is mounted above a water storage tank. Water is pumped from the storage tank at low head (usually 12 to 2 0 foot) and distributed over the plates where it flows in a thin film down the plates and returns to the storage tank by gravity. If the water temperature is warm, the machine functions as a Baudelot chiller. If the water temperature is low, some of the water is frozen on the plates into sheets of ice about 3/16" to 1/4" thick. Periodically the ice is released from 1/12 to 1/3 of the plates by reversing the refrigerant flow to Complete packages with evaporative condensers are available in sizes from 7.5 tons to 150 tons. Complete packages for use with remote condensers are available in sizes from 7.5 tons to 300 tons. THERMAL STORAGE STRATEGIES Daily Load Shifting Weekly Load Shifting Daily Load Leveling Weekly Load Leveling Operating Mode The cool storage operating mode desired determines the size of storage capacity required, or the amount of space available for storage influences the operating mode selected. Load Shifting/Full Storage The load shifting system provides enough storage to meet a building's full on-peak cooling requirements. The building load profile in Figure 1 illustrates how the cooling load demand occurs in a conventional cooling system. Figure 3 shows how full storage displaces the cooling demand to times when other electrical loads (noncooling loads, e . g . lighting and motors) are negligible and during "shoulder hours" when the loads start to increase prior to normal building occupancy. As a result, all storage cooling occurs during off-peak periods thus affecting demand cost savings. these plates. By not allowing the ice thickness to build up, heat transfer is kept high, a distinct advantage over conventional ice builders. The equipment is available as an R model (remote) in which only the plates, refrig erant piping, valves, accumulator, and refrigerant controls are packaged for con nection to remote refrigeration condensin units in sizes from 7.5 tons to 300 tons. A complete package utilizing evaporator section, compressor, water cooled condenser, all controls and single point electrical connection is available in sizes from 7.5 tons to 245 tons.

Proceedings of the Third Symposium on Improving Building Systems in Hot and Humid Climates, Arlington, TX, November 18-19, 1986

ESL-HH-86-11-06

Load LevelingIPartial Storage

A partial storage system runs many more hours than a full storage system, so less demand reduction is obtained. However, partial storage is initially less expensive than full storage because less storage capacity is required, and because smaller capacity refrigeration equipment is used.

The plates are grouped in sets of two or three, such that the heat of rejection from'the active plates is used to provide the heat to harvest one set at a time. The ice generator will operate as a chiller when warmer than 3 2 " ~ water is supplied to the plates. Depending on the compressor capacity, plate length and water flow rate, with a water temperature on the plate of 55"F, the leaving water will be between 45F and 33F. In Figure 7 chilled water is pumped from the storage tank to the load and returned to the ice generator. A low head recirculation pump is used to provide optimum flow over the heat exchanger as required. The system may be applied to load leveling or load shifting applications. In load leveling applications, when no building load is present, ice is generated and the storage tank is charged. When a building load is present, the return chilled water flows directly over the plates and the ice generator functions as a high efficiency chiller. In load shifting applications, the ice load is present during off-peak hours. When a load is present during off-peak hours, the ice generator will behave as a chiller as in the load leveling application. By decoupling the ice generation from the storage, additional capacity can be obtained without the addition of compressor capacity or heat exchange surface. This is accomplished by adding compressor run time. Weekend hours which are usually off peak can be used to generate ice. Weekend ice is then stored for supplemental use during the week. In this application a larger storage tank is used to store the weekend ice. A characteristic of ice formed by building on flat plate heat exchangers is the ability to melt the ice that is stored in the tank very quickly. The ice is characteristically less than 6" x 6 " x 0.25" with a stacking density of 25 to 3 0 pounds per cubic foot. The ice contact area with the return water is quite large and the water velocities through the stack are quite low. A twenty-four hour charge of ice in the storage tank can be melted in less than 3 0 minutes. Ice stored in this fashion may be used for emergency cooling systems requiring large capacity for short durations. Refrigeration systems used with this system may be reciprocating, screw, or centrifugal. Suction temperatures are relatively constant between 20F and 21F. Condensing temperatures will vary with the type of heat rejection used and the ambient conditions. As with any ice generation system, evaporative condensers or cooling

When load leveling cool storage mode is used, capacities of the storage system and refrigeration equipment are selected so the design-day cooling load can be met by continuous operation of the refrigeration equipment. This strategy minimizes compressor capacity requirements and significantly reduces the space cooling contribution to the building's peak demand. AS illustrated in Figure 4 , the overall effect of this operating mode is to level the cooling component of the building's load. During peak hours, part of the cooling load is met directly by the compressor and part by storage. The storage required for the partial mode of operation must be adequate to supply all the building cooling load not met directly by the refrigeration equipment. I n the situation illustrated in Figure 4 , about 6 0 percent of the building's peak-hour cooling load would be supplied from storage. The fraction met by the compressor increases on either side of the peak until, during "shoulder" hours, compressor output exceeds the direct cooling load and part of the compressor output goes into storage. During off-peak hours, the refrigeration equipment is devoted entirely to cooling the storage medium. Weekly cycles use the same principle but allow storage of ice 'on weekends, thereby reducing the size for the refrigeration system and increasing the tank size. EQUIPMENT OPERATION AND SIZING Harvesting Ice Generators and Storage Systems Harvesting ice generators separate the function of making ice and storing ice. Ice is formed on the outside of flat plate heat exchangers arranged in vertical banks to an economic thickness usually not greater than 0.25 inches. The ice is harvested by introducing hot refrigerant gas into the inside of the heat exchanger plates. The hot gas warms the plate breaking the bond between the ice and the plate. The ice drops off into a storage tank. Figure 5 shows a schematic of the plate generating ice and harvesting ice. Figure 6 shows the application of ice storage for a chilled water air-conditioning application. Ice is generated on the plates by circulating 3ZF water for a 2 0 to 3 0 minute build cycle and harvesting in 2 0 to 4 0 seconds.

Proceedings of the Third Symposium on Improving Building Systems in Hot and Humid Climates, Arlington, TX, November 18-19, 1986

ESL-HH-86-11-06

t o w e r s a r e recommended ton.

t o m i n i m i z e t h e kw/

Sizing the i c e generator should take i n t o a c c o u n t t h e number o f h o u r s t h a t t h e system r u n s a s a c h i l l e r and i c e g e n e r a t o r . Approximate s i z i n g can be o b t a i n e d from the following relation: I = T-H/(NHI WHERE
I = ICE M A K I N G CAPACITY T-H = TON HOURS REQUIRED N H I = NUMBER OF HOURS I N THE ICE M A K I N G MODE N H C = NUMBER OF HOURS I N THE CHILLER MODE

1.3

NHC)

S t o r a g e r e q u i r e m e n t s may b e a p p r o x i m a t e d a s follows:
V

WHERE

1o:m

11:m noon 1:00 2:00 3:00 4:00 5:00 6:00 7:00 8:00 9:00

1o:m

5:00 6:W 7:00 8:00 9:00

11:m
ON PEAK 1125.00 1105.40 1105.40 1105.40 1105.40 OFF IFIAK 1163.76 962.11 %2.11 %2.11 962.11
0.00 0.00

NHI

83.3/DI

V = VOLUME D I = DENSITY OF ICE I N STACK

5546.60 5012.20

(DI = 27.8 APPLICATION EXAMPLES

lb/ft3) Table 1

The l o a d p r o f i l e i n F i g u r e 1 r e p r e s e n t s a Tuesday load on a t y p i c a l o f f i c e b u i l d i n g . F i g u r e 2 s h o w s t h e t y p i c a l Monday c o o l i n g load. The d i f f e r e n c e i n t h e two p r o f i l e s i s the residual heat stored i n the buildi n g o v e r t h e weekend. In the sizing examples t h a t follow, Table 1 i s used t o show t h e p r o f i l e . For each d a i l y s t r a t e g y t h e compressor/refrigeration s y s t e m w i l l b e s i z e d f o r T u e e d a y l o a d s and weekend h o u r s w i l l be used t o s t o r e e x t r a c o o l i n g t o m e e t t h e Monday d r a w d o w n l o a d s . ENERGY DEMAND THERMAL STORAGE S I Z I N G EXAMPLE: 9 0 , 0 0 0 f t 2 OFFICE BUILDING EXAMPLE INCLUDES : DESIGN WEEK LOAD PROFILE. DAILY LOAD LEVELING S I Z I N G . WEEKLY LOAD LEVELING S I Z I N G . DAILY LOAD SHIFTING S I Z I N G . WEEKLY LOAD SHIFTING S I Z I N G . SELECTION SUMMARY. SYSTEM F I R S T COST COMPARISON. SIMPLE PAYBACK ANALYSIS DESIGN WEEK LOAD PROFILE FOR 90.000 F T ~ OFFICE BUILDING

2.

DAILY LOAD LEVELING EXAMPLE Sizing Conditions Peak period d u r a t i o n 8 hours (12:OO 8 pm)

Occupied period 1 2 h o u r s 6 h o u r s on-peak 6 hours off-peak Tueeday l o a d 2067.51 ton-hr Monday l o a d i n c l u d i n g d r a w down i s 2288.76 ton-hr

A.

D a i l y Load L e v e l i n g T u e s d a y Load

Based on

COMPRESSOR TONS = (2067.51/(12+1.3(12)) = 75.0 STORAGE = (75.0 t o n ) ( l 2 h r ) = 900 ton-hr VOLUME = (900 ton-hr) ( 3 f t3ton-hr) = 2,700 f t 3 B. D a i l y Load L e v e l i n a Based on Monday D r a w Down L o a d

tons

= 75.0

COMPRESSOR TONS TONS STORAGE = 900 + (2288.76 = 1.121 ton-hr

2067.51)

Proceedings of the Third Symposium on Improving Building Systems in Hot and Humid Climates, Arlington, TX, November 18-19, 1986

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3.

WEEKLY L O A D LEVELING EXAMPLE Sizing Conditions P e a k eriod duration 8 hours 8:00 pm) (12:08 o c c u p i e d period 12 hours - 6 hours on-peak 6 hours off-peak Total weekly load 10,558.00 ton-hr

STORAGE (77 ton)(4 48 6 ) hr = 4,466 ton-hr VOLUME = (4466 ton-hr)(3 ft3/ton= 4466 ton- r 3ft31ton-hr) = 13,398 f t b ) (
=

6.

EQUIPMENT AND STORAGE SELECTION USING QUICK SIZING CHARTS Sizing Conditions P e a k ueriod 8 hours (12:OO-8:00 pm) occupied period 1 2 hours 6 hours on-peak 6 h o u r s off-peak

A.

Weekly Load Leveling - Based on T o t a l Weekly Cooling Load .COMPRESSOR T O N S = 10558.00/(5(12)(1.3)+5(12)+48) = 57.0 tons STORAGE = (57.0 ton)(6 + 24 + 24 + 6 ) = 3,420 ton-hr VOLUME = (3420 ton-hr) (3 f t3/ton-hr) = 10,260 ft3

SUMMARY FROM QUICK SIZING CHART

4.

DAILY L O A D SHIFTING Sizing Conditions P e a k period duration 8 hours 8:00 pm) (12:OO Occupied period 1 2 hours 6 hours on-peak 6 hours off-peak Tuesday load 2067.51 ton-hr Monday load including draw down is 2288.76 ton-hr

E m I W E (lNPmmR CN-PEAK TWR* TONS~SST/(KW~ K)W ~ C Conventional 0 0 225/%/1.2 270 Daily Level 1121 3363 75/20/1 9813510.9 BlO IhilyShift O l381 4143 116/20/1 15113510.9 74/35/0.9 67.5 Weekly L a d 3420 10260 57/20/1 WeeklyShift 4466 13398 77/20n 100/35/0.9 0
SIIWX

X+

*
7.

Daily strategies irrLude Waxlay draw dam load storage. k* AlSOes evaporatively cooled d e n s e r KW.

F I R S T COST EQUIPMENT COMPARISON WITH CONVENTIONAL*

A.

Daily Load S h i f t i n g Tuesday Load

Based on A . C o m R n t i d Chiller 225 Ton (2 1 1 2 . 5 ton chillers at $300/ton) B . Daily Level Ice Maker Evaporative Condeneer Rebate ($250)(270+3) Storage C. ~aily~hift- ~ c e W r Evaporative Condeneer Rebate ($250)(270) Storage D. Weekly Level- Ice W r EvapDrative Condeneer Rebate ($250)(270-72) storage E. Weekly Shift Ice W r Evaporative Condenser Rebate ($250)(270) Storage $67,500

COMPRESSOR TONS = (2067.51/(6(1.3)+10) = 116.0 t o n s STORAGE = (116.0 ton)(lO hr) 1,160 ton-hr VOLUME = (1160 ton-hr) (3f t3/ton-hr) 3,480 ft3

$62,000 15,UX) -43,000 16,000

$%UX)

B.

Daily Load S h i f t i n g - Based on Monday D r a w Down Load

w,m

5.

COMPRESSOR TONS = 116.0 tons STORAGE = 1 1 6 0 ton-hr + (2288.76-2067.51) = 1,381 ton-hr VOLUME = (1381 ton-hr) (3f t3/ton-hr) = 4,143 ft3 WEEKLY L O A D SHIFTING Sizing Conditions P e a k period duration 8 hours 8:00 pm) (12:00 Occupied period 1 2 hours 6 hours on-peak 6 hours off-peak T o t a l weekly load 10558.00 ton-hr

$96 ,000 20,600 47,500 18,000 $67,100 $67.100

A.

Based on Weekly Load Shifting T o t a l Weekly Cooling Load COMPRESSOR TONS =(10558.00/(5(6)(1.3)+5(6)+5(4)+48) = 77 tone

No credit for d l e r piping, wiriq, traneformers, circuit bmdrera, etc. with t h e d storage.
receiver, suction acamiLatDr, valves, ard refrigerant p i $ % .

** Price k r l u l e s evaporator section, oompreseor, motor.

Proceedings of the Third Symposium on Improving Building Systems in Hot and Humid Climates, Arlington, TX, November 18-19, 1986

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8.

SIMPLE P A Y B A C K ANALYSIS Demand Savinge: DPL

approximately $ ~ O / K W shifted a n n u a l s a v i n g s (based o n p e a k demand for four summer m o n t h s w i t h 8 0 % ratchet at $7.65/KW demand charge)

LOAD PROFILE

D a i l y L e v e l (270-98)($80/~W) -$13,760 21,600 D a i l y Shift (270)($80/Kw) W e e k l y Level(270-72)($80/~~) 15,840 21,600 Weekly Shift (270)($80/KW) E n e r g y Savings: D P L r a t e s a p p r o x i m a t e l y $0.046 $0.046 (including f u e l adjustment) EFLH = 1400 on-peak off-peak

---

TIME - HOUR X - TUESDAY FIGURE I

LOAD PROFILE
Weekly Shift 100% off-peak t o n ) ( w . 0 4 6 ) (1400)(.98raJ/m)(225

= $14,200

S i m p l e Payback:

ComRntfanal $67,506

WlyLevel Daily Shift Veekly Lmel Myshift CONCLUSION:

9 , 3 3 3 67,000 42,710 51,8M)

0 0 0 0 0

0 $13,760 2l,600 15,840 2l.W

0 $3,701 3,475 3,629 3,185

0 . 0 0 . 0 0 . 0 0.0 0 . 0

5
0

Harvesting ice makers a r e a n e f f e c t i v e t o o l i n t h e utility load management plan. By reducing installed r e f r i g e r a t i o n capacity, o r insuring that equipment doee not r u n o n peak, t h e s a m e g e n e r a t i n g c a p a c i t y c a n s e r v e many m o r e cuetomers. Turbo R e f r i g e r a t i n g C o m p a n y m e e t s thie need by providing high efficiency, l o w maintenance, and highly r e l i a b l e t h e r m a l s t o r a g e eyetems.

9 11 13 15 17 19 21 23 TIME - HOUR MONDAY X - TUESDAY

FIGURE 2

Proceedings of the Third Symposium on Improving Building Systems in Hot and Humid Climates, Arlington, TX, November 18-19, 1986

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I C E MAKER PLATE MOOULE

&IR H A W

COX

MILLED WATER PVYP

WATW R E C I R L U T I O N RIP

FIGURE 7

Proceedings of the Third Symposium on Improving Building Systems in Hot and Humid Climates, Arlington, TX, November 18-19, 1986

ESL-HH-86-11-06

LOAD PROFILE

ICE MAKING
WATER DISTRIBUTION PAN SUCTION HEADER

't

CHECK VALVE

..
ORIFICE

LIOUIO HEADER

9 1 1 13 15 17 19 21 23
TIME
X

FIGURE 5

- HOUR TUESDAY

FIGURE 3

I C E HARVESTING

LOAD PROFILE
220 2001801600

0
V)

14012010060 0

807,-o.so.dl

;qJ,,
1

.I@o.oo-00-00.00-OG $.o.@o.s 0.0

ORIFICE
,

,
I r .

FIGURE 6

9
X

1 1 13 15 17 1 9 2 1 2 3

TIME

HOUR TUESDAY

FIGURE 4

Proceedings of the Third Symposium on Improving Building Systems in Hot and Humid Climates, Arlington, TX, November 18-19, 1986